Allmand Nl Pro Lite

1

NIGHT-LITE PROSERIES

OPERATOR’S MANUALALLMAND BROS. INC

P.O. BOX 888HOLDREGE, NE 68949

PHONE: 308/995-4495, 1-800/562-1373ALLMAND FAX: 308/995-5887

ALLMAND PARTS FAX: 308/995-4883

NIGHT-LITE SERIES

NIGHT-LITE

August 2007

For Parts and Updates visit Allmand on the Web at www.allmand.com

2

INSPECTION CHECK LIST

FOR PREPARING THE NIGHT-LITE PRO FOR DELIVERY OR RENTAL

The NIGHT-LITE PRO requires service as well as proper operation in order to provide theperformance and safety it has been designed for. Never deliver or put a machine into servicewith known defects or missing instructions or decals. Always instruct the customer in theproper operation and safety procedures as described in the operator’s manual. Alwaysprovide the manual with the equipment for proper and safe operation.

CHECK LIST:Visually inspect the equipment to ensure that all instructions and decals are in place andlegible.Inspect the tower latch and knob assembly which locks the tower in the vertical position forproper operationCheck the hitch assembly and safety tow chainsCheck the outriggers and jacks to make sure they operate properlyInspect the light assemblies for damage and test for proper operationInspect the electrical wiring for signs of damageCheck the ground rod cable and the ground lug. Make sure they are clean, undamaged,and functional.Inspect the tires to ensure good condition and proper inflationCheck oil, fuel, coolant levels, and hydraulic fluid levels.Check to make sure the operator’s manual is with the equipment.Inspect the machine physically for damage and repair if necessary.

NOTE: See appropriate section of manual for scheduled maintenance intervals.

After completing the inspection check list, operate the tower through a completeoperation cycle, following the operating instructions in the operator’s manual.

! WARNINGNEVER ALLOW ANYONE TO OPERATE THE EQUIPMENT WITHOUT

PROPER TRAINING! ALWAYS READ THE INSTRUCTIONS FIRST!

3

TABLE OF CONTENTS

INSPECTION CHECK LIST ..................................................................................................... 2

TABLE OF CONTENTS ........................................................................................................... 3

INTRODUCTION ...................................................................................................................... 4

SAFETY SYMBOL INFORMATION .......................................................................................... 4

SAFETY AND WARNING DECALS ...................................................................................... 5-7

MANUAL WINCH MAST OPERATION.................................................................................. 8-9

ELECTRIC WINCH MAST OPERATION ............................................................................10-11

SPECIFICATIONS ............................................................................................................. 12-14

STARTING INSTRUCTIONS ............................................................................................. 15-16

SERIAL NUMBER LOCATIONS ....................................................................................... 17-18

CONTROLS AND COMPONENTS ................................................................................... 19-25

ROUTINE MAINTENANCE SCHEDULE ............................................................................... 26 KUBOTA D905, D1105, CAT 1.1C, and LOMBARDINI LDW 1003

TROUBLESHOOTING ........................................................................................................... 27

ASSEMBLY PARTS AND ACCESSORIES ........................................................................... 28

4

This manual provides the information necessary for the safe operation of the AllmandBros., Inc., NIGHT-LITE PRO light tower.

The NIGHT-LITE PRO standard tower configuration is operated with two manual crankwinches or single electric winch used to erect, extend, and lower the tower.

Specific operating instructions and specifications are contained in this publication tofamiliarize the operator and maintenance personnel with the correct and safe proceduresnecessary to maintain and operate the equipment.

Take time to read this book thoroughly. If you are uncertain about any of the informationpresented in the manual, contact the factory or your dealer for clarification before operation.

INTRODUCTION

The purpose of the SAFETY INFORMATION SYMBOL shown below is to attract your specialattention to safety related information contained in the text.

!

!

!

DANGER

WARNING

CAUTION

FAILURE TO UNDERSTAND AND COMPLY WITH SAFETY RELATED INFORMATIONALINSTRUCTIONS MAY RESULT IN INJURY TO OPERATOR OR OTHERS. IF YOU DO NOTUNDERSTAND ANY PART OF THIS INFORMATION CONTACT YOUR DEALER FORCLARIFICATION PRIOR TO OPERATING EQUIPMENT.

NOTE

The word NOTE is used to bring your attention to supplementary information in relation tovarious aspects of proper operation and maintenance.

NOTE: Keep this manual accessible during operation to provide convenient reference.

NOTE: Any reference in this manual to LEFT or RIGHT shall be determined by looking at the trailer from the rear.

SAFETY SYMBOLS

5

SAFETY AND WARNING DECALS

SAFETY WARNINGALWAYS REPLACE ANY SAFETY AND INSTRUC-

TION DECALS THAT BECOME DAMAGED, PAINTED,

OR OTHERWISE ILLEGIBLE.

Refer to these representations of the safetywarning decals used on the NIGHT-LITE toinsure correct ordering if replacing be-comes necessary.

PART NO. 090225Location: Inside left hand door panel. Manual winch models only.

PART NO. 090496Location: Inside left hand door panel. Electric winch models only.

PART NO. 100379Location: Inside left handdoor panel.

PART NO. 090249Location: Inside left hand doorpanel of Kubota engine units.

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PART NO. 090166Location: Side panel onmanual winch models. PART NO. 090163

Location: Inside left handdoor panel.


PART NO. 090084Location: AC control panel. PART NO. 090162

Location: On ballastaccess cover.

PART NO. 090133Location: Inside left hand panelbelow ground lug.

PART NO. 090159Location: Above batteryon tower support insideenclosure.

PART NO. 090474Location: Right side panelon manual winch models.

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PART NO. 090139Location: On rear panel under therear tower support.

PART NO. 090002Location: Light bar cover.

PART NO. 100384Location: Inside left hand doorpanel.

PART NO. 090152Location: Inside left hand doorpanel. (electric winch models)

PART NO. 090003Location: On left front and rearpanel of enclosure. PART NO. 090161

Location: Right hand side ofelectric winch cover.

PART NO. 090179Location: Inside left hand doorpanel.

PART NO. 090160Location: On pintle hitch.

PART NO. 090005Location: Inside left hand door panel.

PART NO. 090164Location: On mast pivotsection.

8

MANUAL WINCH MAST OPERATION

ALWAYS CHECK FOR OVERHEADOBSTRUCTIONS BEFORE RAISINGAND LOWERING MAST. ALLOW 35'CLEARANCE. AVOID ALL OVERHEADELECTRICAL WIRES.

TO PREVENT INSTABILITY AND HELPENSURE SAFE OPERATION, ALWAYSPROVIDE PROPER GROUND SUP-PORT BEFORE RAISING MAST.

BEFORE RAISING MAST, VISUALLYINSPECT EQUIPMENT FOR DAMAGEOR WEAR. FAMILIARIZE YOURSELFWITH THE LOCATION AND FUNCTIONOF ALL OPERATING PARTS BY STUDY-ING THIS MANUAL. OBSERVE ALLCAUTION DECALS LOCATED ONEQUIPMENT

NOTE: The latch locks the mast in thevertical position and disengages thesections allowing the tower assemblyto be rotated to position the lights.

! SAFETY WARNING

TO ERECT MAST AND RAISELIGHTS1. Extend both side outrigger jacks, rear jack

and tongue jack to stabilize and level thetrailer.

NOTE: Jacks should be placed only onfirm footing.

WHEN EXTENDING REAR JACK, WATCHTO ENSURE YOU ARE CLEAR OF THEOVERHANGING ENDS OF THE MASTBEFORE YOU STAND UP.

THE SUPPLEMENTAL GROUND ROD IS ASAFETY DEVICE THAT MAY REDUCETHE CHANCE OF PERSONAL INJURYFROM STRAY ELECTRICAL CURRENT.Therefore, Allmand recommends usingthe ground rod. However, it is the user’sresponsibility to determine the require-ments and/or applicability of local, state,or national electrical code which governsthe use of the ground rod.

! SAFETY WARNING

DESCRIPTION OF OPERATIONThe Allmand NIGHT-LITE tower assemblyconsists of a three section telescopingmast which can be raised and extended byoperating two hand crank winches. Onewinch, mounted with the handle extendingthrough the side of the trailer frame, raisesand lowers the mast from the horizontaltowing position, the vertical position, andback. The second winch mounted on thetower extends the telescopic sections.

The three section mast assembly can berotated from the ground by loosening aknob and rotating the entire assembly 360°to aim the lights as necessary.

2. Attach the ground rod to the grounding lug,and drive the ground rod fully for adequateelectrical ground, as required by local,state, or national code.

3. Release the pin that secures the mast tothe rear mast support.

4. Operate the hand crank on the side of thetrailer to raise the mast from horizontal tovertical.

5. Turn black knob counterclockwise andengage latch in strike plate. Retighten blackknob.

6. Operate the hand crank winch on the towerclockwise to raise the lights vertically.

7. To rotate the lights, release the black knoband turn the tower assembly with thehandles provided.

8. To turn on lights, flip the breaker switches tothe up position. (SEE FIG. 1)

9

MANUAL WINCH MAST OPERATION

IF THE TOWER CANNOT BE ROTATEDAFTER LOOSENING THE BLACK KNOB,CHECK TO ASSURE THE LOWERLATCH IS ENGAGED IN THE STRIKEPLATE. THIS DOUBLE LATCH FEATUREPREVENTS THE TOWER FROM BEINGROTATED IF THE LATCH IS NOT EN-GAGED.

! SAFETY WARNING

NOTE: Ensure the detent pins areproperly engaged in the outriggersbefore towing.

! SAFETY WARNINGVISUALLY INSPECT EQUIPMENT FORDAMAGE BEFORE OPERATING. ALLOWADEQUATE CLEARANCE AROUNDTRAILER FOR TOWER AND INSURE THATNO PERSONS ARE STANDING IN FRONTOF OR BEHIND UNIT WHEN LOWERING.

TO LOWER MAST AND LIGHTS

1. Turn off lights.2. Release black knob and rotate tower until

winch handle points to the front of the trailerand retighten knob.

3. Operate hand crank winch on tower counter-clockwise to lower the lights to the lowestvertical position

4. Operate hand crank winch on side of trailerclockwise to take up any cable slack.

5. Turn the black knob counterclockwise and lift torelease the latch from the strike plate. Re-tighten the knob with the latch disengaged fromthe strike plate.

6. Operate the hand crank on the side of thetrailer counterclockwise to fold the mastdown into the towing position.

NOTE: Sufficient load (75 lb. min ) mustbe applied to the cable to overcomeinternal resistance and operate thebrake properly. Insufficient load will notturn the reel thus continual turningwithout sufficient load will remove thewinch handle from the shaft.

7. Secure light cords into hook on the reartower support for towing.

8. Secure pin locking mast to rear towersupport.

9. Remove ground rod from earth. Discon-nect wire from ground lug and secure intrailer

10. Raise jacks and rear stand, retractoutriggers and secure for towing

NOTE: Visually inspect the flood light mounting yokes for loose hardware. This could pre-vent a broken fixture during towing.

10

ELECTRIC WINCH MAST OPERATION

DESCRIPTION OF OPERATION

The Allmand NIGHT-LITE tower assemblyconsists of a three section telescoping mastwhich can be raised and extended by operat-ing a single electric winch mounted inside theenclosure. A single three position toggle switchmounted on the control panel is used to raiseand lower the mast. The winch and cable areprotected by an integral clutch and a circuitbreaker. The clutch is designed to slip whenthe mast reaches full extension. The circuitbreaker is a safeguard for the clutch. If theclutch is misadjusted or inoperative the circuitbreaker should trip to protect the system fromoverload. The electric winch operates off the120 volt circuit breaker along with 120 voltreceptacle thus requiring that the 120 voltcircuit breaker switch must be on to oper-ate the winch.The three section mast assembly can berotated from the ground by loosening a knoband rotating the entire assembly 360° to aimthe lights as necessary.

ALWAYS CHECK FOR OVERHEAD OB-STRUCTIONS BEFORE RAISING ANDLOWERING MAST. ALLOW 35' CLEAR-ANCE. AVOID ALL OVERHEAD ELECTRI-CAL WIRES.

TO PREVENT INSTABILITY AND HELPENSURE SAFE OPERATION, ALWAYSPROVIDE PROPER GROUND SUPPORTBEFORE RAISING MAST.

WHEN EXTENDING REAR JACK, WATCHTO ENSURE YOU ARE CLEAR OF THEOVERHANGING ENDS OF THE MASTBEFORE YOU STAND UP.

THE SUPPLEMENTAL GROUND ROD IS ASAFETY DEVICE THAT MAY REDUCE THECHANCE OF PERSONAL INJURY FROMSTRAY ELECTRICAL CURRENT. There-fore, Allmand recommends using theground rod. However, it is the user’sresponsibility to determine the require-ments and/or applicability of local, state, ornational electrical code which governs theuse of the ground rod.

2. Attach the ground rod to the grounding lug,and drive the ground rod fully for adequateelectrical ground, as required by local, state,or national code.

3. Start engine and switch the 120 volt circuitbreaker switch to the ON position.

4. Release the pin that secures the mast to therear mast support.

5. Push the toggle switch in the up position toraise the mast from horizontal to vertical.

TO ERECT MAST AND RAISELIGHTS1. Extend both side outrigger jacks, rear jack

and tongue jack to stabilize and level thetrailer.

NOTE: Jacks should be placed only onfirm footing.

BEFORE RAISING MAST, VISUALLY INSPECTEQUIPMENT FOR DAMAGE OR WEAR. FA-MILIARIZE YOURSELF WITH THE LOCATIONAND FUNCTION OF ALL OPERATING PARTSBY STUDYING THISMANUAL. OBSERVE ALL CAUTION DECALSLOCATED ON EQUIPMENT

NOTE: The latch locks the mast in thevertical position and disengages thesections allowing the tower assembly tobe rotated to position the lights

SAFETY WARNING!!

SAFETY WARNING!!

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IF THE TOWER CANNOT BE ROTATEDAFTER LOOSENING THE BLACK KNOB,CHECK TO ASSURE THE LOWER LATCHIS ENGAGED IN THE STRIKE PLATE.THIS DOUBLE LATCH FEATURE PRE-VENTS THE TOWER FROM BEING RO-TATED IF THE LATCH IS NOT ENGAGED.

VISUALLY INSPECT EQUIPMENT FORDAMAGE BEFORE OPERATING. ALLOWADEQUATE CLEARANCE AROUNDTRAILER FOR TOWER AND INSURE THATNO PERSONS ARE STANDING IN FRONTOF OR BEHIND UNIT WHEN LOWERING.

TO LOWER MAST AND LIGHTS1. Turn off lights.2. Release black knob and rotate tower

until winch handle points to the frontof the trailer and retighten knob.

3. Operate electric winch toggle switchin the down position to lower thelights to the lowest vertical positionuntil the latch clicks.

4. Operate electric winch in the UPposition to take up any cable slack.

5. Turn the black knob counterclock-wise and lift to release the latch fromthe strike plate. Retighten the knobwith the latch disengaged from thestrike plate.

6. Operate the electric winch toggle switchDOWN to fold the mast down into thetowing position.

7. Replace latch pin.8. Stop engine.9. Secure light cords into hook on the rear

tower support for towing.10. Secure pin locking mast to rear tower11. Remove ground rod from earth. Discon-

nect wire from ground lug and secure intrailer

12. Raise jacks and rear stand, retractoutriggers and secure for towing

NOTE: Ensure the detent pins are properlyengaged in the outriggers before towing.

AUXILIARY HANDLEAn emergency crank handle is providedfor use in the event of a power failure.

1. Remove the electrical power from thewinch

2. Insert the handle so that it completelyengages with the driveshaft. Thehandle can be cranked in eitherdirection with the clutch in the en-gaged position.

3. Always remove the handle from thewinch after use.

NEVER OPERATE THE WINCHELECTRICALLY WITH THE EMER-GENCY HANDLE IN POSITION.

ELECTRIC WINCH MAST OPERATION

SAFETY WARNING!!

SAFETY WARNING!!

SAFETY WARNING!!

6. Turn black knob counterclockwise andengage latch in strike plate. Retightenknob.

7. Remove latch pin.8. Release the latch by squeezing the

handle and push the toggle switch to theUP position to raise lights

9. To rotate the lights, release the blackknob and turn the tower assembly withthe handles provided

12

SPECIFICATIONS

OVERALL DIMENSIONS

Weight 1600 LBSLength 13' 6" (4.04 m)Height lowered 6' 1" (1.85 m)Height extended 30' (9.14 m)Width ( outriggers retracted ) 4' 1 1/2" (1.26 m)Width ( outriggers extended ) 7' 9 1/2" (2.37 m)Trailer steel frame, leaf spring axleWheels and tires 13"

Low oil pressure and high engine temperature shut-downs are standard equipment. BothThe Kubota, CAT, and Lombardini diesel are equipped with glow plug cold start assist asstandard equipment.

NOTE: See the appropriate section of this manual for cold weather starting instructionsor consult the Operators Manual for your particular engine application.

Horsepower ratings are established in accordance with Society of Automotive EngineersSmall Engine Test Code- J1349 GROSS.

MODEL KUBOTA D905 KUBOTA D1105 LOMBARDINI LDW 1003 CAT C1.1

TYPE Water cooled 4-cycle diesel Water cooled 4-cycle diesel Water cooled 4-cycle diesel Water cooled 4-cycle diesel

BORE 2.83" (72 mm) 2.99" (76 mm) 2.96" (75 mm) 3.03" (77 mm)STROKE 2.90" (73.6 mm) 2.90" (73.6 mm) 3.05" (77.6 mm) 3.19" (81 mm)DISPLACEMENT 54.9 cu. In (898 cc) 61.1 cu. In (1002 cc) 62.6 cu. In (1028 cc) 69 cu. In (110 cc)

POWER @ 1800RPM 10.5 HP (8.8kw) 13.6 HP (11.4kw) 13.4 HP (11.2kw) 12.3 HP (10.3kw) derate 14.3 HP (11.9kw) non derate

POWER OUTPUT DERATING

3% per 1000 ft above 360 ft. 1% per 10° above 77° F




FUEL SYSTEM Indirect injected diesel Indirect injected diesel Indirect injected diesel Cassette type fuel injected diesel

STARTING SYSTEM 12 volt DC 12 volt DC 12 volt DC 12 volt DC

COMPRESSION RATIO

22:1 22:1 22.8:1 22:1

WEIGHT 205 lbs (93 kg) 205 lbs (93 kg) 191 lbs (87 kg) 191 lbs (87 kg)

OIL CAPACITY 5.4 qt. (5.1 L) 5.4 qt. (5.1 L) 2.5 qt. (2.4 L) 3.9 qt. (3.7 L)

LUBRICATION Forced lubrication by pump Forced lubrication by pump Forced lubrication by pump Forced lubrication by pump

OIL FILTRATION Cartridge type Cartridge type Cartridge type Cartridge type

COOLING SYSTEMPressurized radiator, forced circulation with water pump

Pressurized radiator, forced circulation with water pump



ENGINE SPECIFICATIONS

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SPECIFICATIONS

GENERATOR

6 kw and 8 kw models available60 hz and 50 hz models available 332RSA1020

FUEL REQUIREMENTSUse a clean No. 2 Diesel fuel oil (SAE J313 JUN87) according to ASTM D975. Do not usealternative fuel, because its quality is unknown or it may be inferior in quality,and kerosene,which is very low in cetane rating, adversely effects the engine. Refer to the Kubota,Perkins, or Isuzu Operators Manual for more detailed fuel requirements.

ENGINE OIL REQUIREMENTSUse a high quality engine oil of API (American Petroleum Institute)service class CC/CD/CE Refer to the Kubota, CAT, or LombardiniOperator’s Manual for more detailed engine oil requirements.

KUBOTA LUBRICATION CHART

CAT LUBRICATION CHARTLOMBARDINI LUBRICATION CHART

14

SPECIFICATIONS

TRAILER

The complete generator is housed in a lockable enclosure with the frame fabricated fromheavy gauge steel mounted on a two - wheel, leaf spring axle.The design enables the trailer to contain the outriggers in a simple, compact position.

When the mast is in the operating position it is located in the middle of a three pointoutrigger system for optimum balance and stability. This system was engineered to allowthe light tower to remain operational in sustained winds of 65 MPH with the mast extendedto full height and the outriggers in position.

MAST

The mast consists of a three section steel tube that extends to 30 feet.The mast is extended with two manual winches.The mast includes self lubricating nylonguide pads and a 360 degree rotatable light bar .

STABILIZERS

The three point outrigger design consists of two retractable side outriggers and a tonguejack.

FLOOD LIGHT ASSEMBLY

The flood light assembly consists of four 1000 watt or 1250 watt lamp fixtures sealed for allweather use.

SHO 1000 fixture - Metal Halide LampLumen rating: 110,000Warm up time: 2-4 minutesRestart time: 10-15 minutes

TOWING INSTRUCTIONS

Before towing the Night-Lite Pro the trailer should be inspected visually to insure that thefollowing operations have been completed:

1. Hitch is securely attached to the towing vehicle (safety chains securely attached2. All outriggers and jacks are retracted and secured.3. Rear tower support pin is in the locked position.4. Light fixtures are positioned for transport.5. Doors are closed and secure.6. Check for adequate tire pressure.7. Tail lights are connected and operational.8. Ground rod is removed from ground and secured in trailer.

SHO 1250 fixture - Metal Halide LampLumen rating: 150,000Warm up time: 2-4 minutesRestart time: 10-15 minutes

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STARTING INSTRUCTIONS

BEFORE STARTING:1. Fill the engine with the right grade of lubricating oil (refer to the proper page of this manual or the Kubota,

CAT, or Lombardini diesel operators manual for oil specifications)2. Ensure there is an adequate supply of diesel fuel.3. Ensure that the air cleaner is firmly attached and air cleaner seals and hose clamps are

properly sealed. Air cleaner element should be checked and replaced if necessary.

STARTING ENGINENOTE: The Kubota D905 and D1105, CAT C1.1, and Lombardini LDW 1003 diesel engines include a glowplug cold start system controlled by the ignition switch on the control panel. Glow plugs are not needed on awarm engine or if the ambient temperature is above 50 degrees F.

COLD WEATHER STARTING: KUBOTA and LOMBARDINI LDW 1003 (for temperatures below 32° F/ 0° C)1. Turn the key switch to the PREHEAT position, hold until the glow plug indicator lamp goes out,

then release switch.2.Turn the key switch to the START position and the engine should start. Release the key immediately when the engine starts. If engine fails to start it may be necessary to cycle the glow plugs again (see chart below)

PREHEATING TIMEAMBIENT TEMPERATURE Ordinary heat type With glow plug timerAbove 50°F (10°C) NO NEED50°F (10°C) to 23°F (-5°C) Approx. 5 secondsBelow 23°F (-5°C) Approx. 10 secondsLimit of continuous use 20 seconds

Automatic preheating ismade for about 6 secondswhen starter switch key isturned to preheatingposition

NOTE: Do not operate starter for more than 10 seconds without allowing 30 secondsto pass between starting attempts. Possible starter damage could result fromexcessive heat caused by cranking too long.

NOTE: If the engine develops sufficient speed to disengage the starter but does not keeprunning (a false start), the engine rotation must be allowed to come to a complete stopbefore attempting to restart the engine. If starter is engaged while the flywheel is rotating,the starter pinion and flywheel ring gear may clash, resulting in damage to the starter orflywheel ring gear.

NOTE: If the starter does not turn the engine over, stop cranking immediately. Do not make further attempts to start the engine until the condition is corrected. See your local Kubota Engine Service Dealer for trouble analysis

COLD WEATHER STARTING: KUBOTA D905 and 1105 Power Unit1. Turn the key switch to the PREHEAT position, hold for 5 seconds, then release switch.2. Depress the START ASSIST button and turn the key switch to the START position and the engineshould start. Release the key immediately when the engine starts. Hold the START ASSIST button forfive seconds after the engine starts then release. If engine fails to start it may be necessary to cyclethe glow plugs again (see chart below).

IF ENGINE HAS RUN OUT OF FUEL:1. Hold the START ASSIST button for 10 seconds and then release. This will allow the fuel system to

re-prime itself.2. Follow normal starting procedures.

16

STARTING INSTRUCTIONS

COLD WEATHER STARTING CAT C1.1 (for temperatures below 32° F/ 0° C)

1. If the engine is cold, turn the key switch counterclockwise to the “preheat” position until theglow plug indicator turns red. CAUTION: Never heat glow plugs more than 5 secondsor damage to the glow plugs may occur.

2. Turn the key switch to the “start” position and start the engine immediately once the indica-tor turns red. Release the key immediately when the engine starts. (If engine fails to start,repeat steps 1 and 2.)

NOTE: Do not operate starter for more than 10 seconds without allowing 30 seconds to passbetween starting attempts. Possible starter damage could result from excessive heat causedby cranking too long.

NOTE: If the engine develops sufficient speed to disengage the starter but does not keeprunning (a false start), the engine rotation must be allowed to come to a complete stopbefore attempting to restart the engine. If starter is engaged while the flywheel is rotating,the starter pinion and flywheel ring gear may clash, resulting in damage to the starter orflywheel ring gear.

NOTE:If the starter does not turn the engine over, stop cranking immediately. Do not makefurther attempts to start the engine until the condition is corrected. See your local ISUZU EngineService Dealer for trouble analysis.

FOR A WARM ENGINE (Kubota, CAT, and Lombardini engines)Follow the same procedure as described for cold weather starting, skipping step 1.Use of the glow plugs is not recommended when engine is warm.

LOW OIL PRESSURE SHUT-OFF SYSTEMShould a low oil pressure condition occur, the oil pressure sending unit breaks the circuitbetween the battery and the fuel solenoid, allowing the spring load to immediately move thefuel control to the shut-off position.

HIGH COOLANT TEMPERATURE SHUT-OFF SYSTEMShould a high coolant temperature condition occur, the temperature sending unit breaks thecircuit between the battery and the fuel solenoid, allowing the spring load to immediately movethe fuel control to the shut-off position.

STOPPING THE ENGINE To stop the engine turn the ignition switch to the off position, this breaks the circuit between the battery and the fuel solenoid, allowing the spring load to immediately move the fuel control to the shut-off position

17

SERIAL NUMBER LOCATION

Trailer: All NIGHT-LITE PRO se-ries trailers have a serial numberplate attached to the rear towersupport below the tower lock.(See illustration)

TRAILER SERIAL NUMBERLOCATION

SERIAL NUMBER LOCATIONS

18

SERIAL NUMBER LOCATIONS

KUBOTA engineserial number

SERIAL NUMBER LOCATION

Generator: The generator has a plate attachedto the side of the housing.

Engine: The KUBOTA engine has the serialnumber stamped on the engine block just belowthe exhaust manifold. (see illustration below )

The ISUZU and PERKINS engines have theserial number stamped on the right side of theengine block just ahead of the first cylinder. (seeillustration below)

The LOMBARDINI engine has the serial numbertag located on the right side of the engine block.(see illustration below)

LOMBARDINI engineserial number

CAT engine serialnumber

19

CONTROLS AND COMPONENTS

NOTE: COMPONENTS SHOWN ARE STANDARD. PICTURES MAY VARY WITH DIFFERENT OPTIONS.

FIG. 1a (CAT)

FIG. 1. A.C./D.C.CONTROL PANEL (Kubota)

FIG. 1a. A.C./D.C.CONTROL PANEL (CAT)

1. Breaker SwitchControls lights 1 and 2


3. Start Assist Button4. Hour Meter

Shows the total elapsed hours of engineoperation.

5. Key SwitchTurn key counter-clockwise to activate theglow plugs.

6. Glow Plug Indicator

NOTE: Release key as soon as the engine fires.

Fig. 1 (Kubota)

1

4

3

5

2

4

6

5

21

20

FIG. 2a. A.C./D.C.CONTROL PANEL (ElectricWinch Model)

1a. Breaker Switches Controls lights 1 through 4

2a. Hour Meter Shows the total elapsed hours of engine operation.

3a. Glow Plug Lamp4a. Key Switch

Turn key counter-clockwise to activate theglow plugs.

5a. Electric Winch On/Off Switch6a. Electric Winch Up/Down Switch




FIG. 1b. A.C./D.C.CONTROL PANEL(Lombardini)

1. Breaker Switch Controls lights 1 and 2


3. Hour MeterShows the total elapsed hours of engineoperation.

4. Key SwitchTurn key clockwise one click to activate theglow plugs.

5. Glow Plug Lamp


FIG. 2a (Electric Winch Model)

6a

2a

3a

4a

5a

1a

1

24

3

5

21



FIG. 4

FIG. 5

FIG. 4. CONVENIENCE PANEL8. Grounding Lug

Attach ground rod lead here9. 15 Amp Pop-up Circuit Breaker10.120 volt Outlet Receptacle with

cover

FIG. 5. GROUND ROD11. Ground rod should be attached to

grounding lug with wire providedand ground rod and then driven fullyinto the earth for adequate electri-cal ground, as required by local,state, or national electrical code.

FIG. 3

FIG. 3. BALLAST PANEL6. Transformer (lights 1 thru 4)7. Capacitors (lights 1 thru 4)

9

10

8

11

22



FIG. 6B

FIG. 6B ENGINE COMPONENT IDENTIFI-CATION (CAT)

16.Water temp switch17.Alternator18.Starter19.Air cleaner

FIG. 6A ENGINE COMPONENT IDENTIFI-CATION (KUBOTA)

12.Water temp switch13.Alternator14.Starter15.Air cleaner

FIG. 6A

FIG. 6C ENGINE COMPONENT IDENTIFI-CATION (LOMBARDINI)

16c. Muffler17c. Alternator18c. Oil Filter19c. Air cleaner (not shown)

FIG. 6C

16c

17c

18c19c

12

13

14

15

16

17

18

19

23

FIG. 7B

FIG. 7A. ENGINE COMPONENT IDENTI-FICATION (KUBOTA cont’d)

20.Oil fill21.Glow plugs22.Fuel solenoid23.Electric Fuel Pump24.Fuel filter25.Oil filter

FIG. 7B. ENGINE COMPONENT IDENTI-FICATION (CAT cont’d)

26.Oil fill27.Glow plugs28.Fuel solenoid29.Fuel pump30.Fuel filter31.Oil filter

FIG. 7C

26c

29c

30c27c

31c

FIG. 7A

23

25

24

2221

20

FIG. 7A

FIG. 7C. ENGINE COMPONENT IDENTI-FICATION (LOMBARDINI cont’d)

26c. Air Cleaner27c. Starter28c. Fuel solenoid29c. Fuel pump30c. Fuel filter31c. Cooling Fan

30

2931

28

27

26

24



SAFETY WARNING

FIG. 8

FIG. 9

FIG. 10

FIG. 8 TOWING COMPONENT IDEN-TIFICATION

32.Tongue jack33.Safety chains34.Pintle hitch35.Hitch (2” ball)

FIG. 9. REAR OUTRIGGERS36.Jack Handle

Crank handle to raise or lower footof jack to level trailer

37.Jack PinPull to allow jack to rotate

38.Outrigger Lock Pin

Be sure outrigger jack is securely latchedusing the outrigger lock pins before tow-ing.

FIG. 10. REAR TOWER SUPPORT39.Pin

Locks tower into the rear tower support40.Tower Interlocking Pin

Keeps tower from extending during towing41.Cord Hanger

Holds lamp cords up during towing

35

34

32

33

36

38

37

25

CONTROLS AND COMPONENTSNOTE: COMPONENTS SHOWN ARE STANDARD.PICTURES MAY VARY WITH DIFFERENT OPTIONS.

42

43

44

45

4647

FIG. 13

FIG. 12

FIG. 11

FIG. 11 POSITIVE DOOR LATCH42.Positive door latch

Locks door in the open position

FIG. 12. MANUAL WINCH HANDLE43.Manual Winch

Crank handle to raise tower from horizontalto vertical position

44.Manual Winch HandleUsed to raise and fold mast

FIG. 13. MANUAL WINCH45.Manual Winch

Extends and lowers mast46.Mast Handle

Used to rotate tower and lights47.Swivel Lock Knob

Locks tower in position

FIG. 13a

FIG. 13a ELECTRIC WINCH45a. Strong Arm Winch—Used to raise and extend, lower and fold mast.46a. Slack Limit Switch-(Located below winchon ballast panel) -Shuts off winch when cable slack is sensed by sensor arm.

NOTE: See pages 10-11, Strong Arm ElectricWinch Mast Operation, for correct operatingprocedures.

45a

46a

26


FIG. 14 MAST LOCKING BAR LATCH48.Mast Locking Bar Latch

Locks mast in the vertical position and allowstower to rotate

NOTE : Tower must be positioned with themanual winch forward before the mast locking barcan be released from the strike plate, allowing thetower to rotate toward the horizontal towing posi-tion.

FIG. 15. KICK-OUT SPRING49.Kick-out spring

Tilts mast off center when folding mast down

FIG. 16. LIFTING ATTACHMENT POINTS50.Forklift Lifting Pockets

Used to lift light tower using forklift to ease loadingand unloading

51.Tower Lifting EyeUsed for lifting light tower using a crane

FIG. 14

FIG. 15

FIG. 16


49

27


FIG. 17

FIG. 17 Electric Mast52. Mast Handle—Use to rotate mast.53. Lock Handle—Pull to unlock tower sections when raising tower.54. Mast Locking Knob—Prevents accidental release of lock when rotating mast.

FIG. 18 Rear Tower Lock Safety Switch55. Safety Switch—Prevents winch operationwhile tower is in the down and locked position56. Safety Switch Actuator cam—Closesswitch and allows tower operation only when inthe UNLOCKED position.

FIG. 18

55

56

54

5352

28

ROUTINE MAINTENANCE SCHEDULEKUBOTA D905, D1105, CAT C1.1, and LOMBARDINI LDW 903

INSPECTION AND LUBRICATION SCHEDULE

Check condition of the steel cable and make sure it is properly secured. Check hydraulic fluid level.

LUBRICATION GREASE SPECIFICATIONS: N.G.L.I. consistency #2, high temperature anti-friction bearing lubricating grease.

Service intervals shown below have been established for operation under normal conditions. Where equipment isoperated under severe conditions (very dusty, extreme heat or cold, etc.) affected items should be serviced morefrequently.

KUBOTA AND ISUZU

CAT C1.1 ONLY

LOMBARDINI ONLY

INTERVAL ITEM PROCEDUREBattery Replace

When Required Engine Air Cleaner Element Clean/Inspect/ReplaceFuel System PrimeFuel Filter/Water Separator Drain oil, flush out system, renew filter element Engine Air Cleaner Serv Indicator Check

Daily Fuel Level Check and fill as necessaryLubricating Oil Check level and conditionCooling System Coolant Check level

50 Hr. Fuel Tank Water and Sediment Drain oil, flush out system, renew filter element Coooling System Coolant Sample ObtainsAlternator and Fan Belts Inspect/Adjust

250 Hr. Engine Oil Sample ObtainBattery Check level of electrolyteEngine Generator Assembly Check for fuel and oil leaks

Every 500 Service Hours Fuel System Secondary Filter Replace with newBattery Electrolyte Level Check

Every 500 Service Hours Engine Air Cleaner Element Replace with newor one year Engine Oil and Filter Change

Radiator CleanHoses and Clamps Inspect/Replace

Every 1000 Service Hours Alternator and Fan Belts Replace with newEngine Valve Lash Inspect/AdjustAlternator Inspect

Every 2000 Service Hours Engine Crankcase Breather Replace with newEngine Mounts InspectStarting Motor Inspect

INTERVAL ITEM PROCEDUREDaily or 10 Hr. Fuel Level Check and fill as necessary

Lubricating Oil Check level and conditionAll 10 Hr. Items As aboveAir Cleaner Service is required. Service requirements

100 Hr. may be accelerated by conditionsBattery Check level of electrolyteEngine Generator Assembly Check for fuel and oil leaks

200 Hr. All 100 Hr. Items As aboveEngine lubricating oil system Drain oil, flush out system, renew filter element

and refill with correct grade and type oil Coolant Check level and condition

400 Hr. Fuel Filter Replace with newAll 200 Hr. Items As above

500 Hr. Fan Belt Check tension and conditionRadiator Clean out fins with water or airAll 500 Hr. Items As aboveEngine Valves Adjust ClearanceCable pulley at the bottom Remove, clean, and grease

1000 Hr. or Yearly of the front mast support Inspect for wear. Clean and lubricateCable pulleys on mast Remove, clean, and greaseAxle Wheel Bearings Clean and repackFuel System Clean sediment from tank

29

TROUBLESHOOTING

DANGER!HIGH VOLTAGE! DO NOT ATTEMPT TO TEST AND REPAIR GENERATOR ANDBALLAST ELECTRICAL SYSTEMS UNLESS YOU UNDERSTAND AND ARE QUALIFIEDTO WORK ON SUCH SYSTEMS.

! SAFETY WARNING

When one lamp does not light, TURN OFF THE GENERATOR and test the lamp by switchingleads with a lamp that DOES light. DO NOT WEAR JEWELRY WHILE WORKING WITHELECTRICITY! If the following procedures do not solve your problem, have the circuit tested by alicensed electrician. DO NOT attempt to test generator voltage or ballast electrical systems unlessyou are a qualified electrician. Consult the factory for voltage specifications and test procedures

PROBLEM POSSIBLE CAUSE1. Circuit breakers in the outlet box are not turned on or have tripped.2. Lamps are not allowed time to cool after last being lit. You mustallow 15 minutes between the time the lights are shut off and the timethey are restarted.3. The lam or lamps are burned out or broken.4. One or more of the lamps are not screwed in securely.5. Plug and socket at light bar not securely pushed together andlocked.6. The temperature of the ballast is below –20 degrees F. the efficiencyof the capacitors in the ballast is not enough to ignite the lamps. Foroperations where the temperatures of the ballasts falls below –20degrees F. some means of warming the ballast must be used.7. Low electrical system voltage.8. A loose connection in the back of the lamp socket in the lamp holder.9. A circuit breaker or breakers are defective.10. A loose connection on the terminal board.11. The engine and generator are not running up to speed (1800 RPM)12. A wrong style replacement lamp (requiring a different ballast) hasbeen installed.13. Too much power is being drawn from the auxiliary outlets.14. Capacitor or transformer have failed.

ONE OR MORE LIGHTSDO NOT LIGHT UP.

15. Corrosion has occurred on the lamp bases.

For engine and generator troubleshooting, see engine and generator manuals orcontact your dealer.

30

PART NO. 090225Location: Inside left hand door panel. Manual winch models only.

PART NO. 090496Location: Inside left hand door panel. Electric winch models only.

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